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13-4
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13-5
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30 Nm (22 ft lb)
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13-6
12 - Thrust washer
Measuring crankshaft axial clearance
page 13-25
Only on 4th crankshaft bearing
13 - Special bolt (12-sided)
Always replace
Driveplate: 60 Nm (44 ft lb) + additional
90 (1/4 turn)
Dual-mass flywheel: 60 Nm (44 ft lb) +
additional 180 (1/2 turn)
14 - Dual-mass flywheel or driveplate
Removing and installing page 13-22
Needle bearing, removing and installing
page 13-21
15 - Crankshaft bearing
Axial and radial clearance, checking
page 13-25
16 - Bolt
10 Nm (7 ft lb)
17 - Oil jet
To cool pistons
18 - Seal for rear flange
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13-7
19 - Bolt
10 Nm (7 ft lb)
20 - Bolt
25 Nm (18 ft lb)
Install hand-tight before fully tightening
21 - Cylinder block
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13-8
CAUTION!
Removing
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13-9
- Counterhold pulley for viscous fan using 3212 spanner wrench and
remove viscous fan using 3312 open-end spanner (left thread).
- Carefully lift out viscous fan.
Note:
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13-10
Installing
- First install ribbed belt onto crankshaft pulley and idler wheel. Push belt
onto tensioning roller last.
Note:
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13-11
Note:
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13-12
Removing
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13-13
WARNING!
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13-14
CAUTION!
Notes:
The toothed belt tensioner is oil dampened. Compress it by slowly
applying constant pressure.
Use spring clamp from 2024A.
- Using 8 mm hex wrench, turn toothed belt tensioning roller -1- counter-
clockwise, opposite direction shown (arrow), until tensioning lever -2-
compresses tensioner -3- so that spring clamp (2 mm dia.) can be
inserted into bore and lifter.
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13-15
Installing
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13-16
Note:
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13-17
- Using 8 mm hex wrench, turn toothed belt tensioner roller -1- counter-
clockwise, opposite direction shown (arrow) until tensioning lever -2-
compresses tensioner -3- so that spring clamp can be removed and
then remove clamp.
- Before starting engine, pre-load timing tensioning roller as follows:
- Using a torque wrench with 8 mm hex bit, apply tension to toothed
belt clockwise in direction shown (arrow) until a torque of 15 Nm is
attained. This ensures tensioner has expanded completely and is
properly engaging toothed belt.
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13-18
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13-19
- Grease threaded head of 2085 seal puller, position and with forced
pressure screw into oil seal as far as possible.
- Loosen knurled bolt and turn inner part against crankshaft until oil seal
is removed.
Installing
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13-20
Dual-mass flywheel
Notes:
Notes:
Do not lubricate sealing lip or outer edge of seal before pressing in.
The assembly aid is supplied with the seal.
- Press in seal up to stop using 2003/3 seal installer and bolts for dual-
mass flywheel or driveplate.
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13-21
- Remove pilot needle bearing using puller -A- (e.g. KUKKO 21/2 and
KUKKO 22/1).
- Install bearing using 3264 bearing driver.
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13-22
Dual-mass flywheel
Note:
Note:
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13-23
Driveplate
- Install driveplate with washer -2- (Part No. 035 105 303 A) and shim -1-
3.0 mm (Part No. 054 105 301) or 4.0 mm (Part No. 054 105 202).
CAUTION!
Part numbers are listed here for reference only. Always check with
your Parts department for the latest information.
Notes:
Short engines and exchange engines are supplied without a bushing
in the crankshaft. Always install a new bushing before installing the
driveplate.
Remove bushing using 21/1 Kukko puller and 21/2 Kukko support.
Always replace driveplate mounting bolts.
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13-24
Note:
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13-25
Axial clearance
CAUTION!
- Attach dial indicator together with VW387 dial indicator holder to oil
pump and set indicator against crankshaft counterweight.
- Press crankshaft against dial indicator by hand and set indicator to
zero.
- Press crankshaft away from dial indicator.
- Read gauge.
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13-26
Radial clearance
- Read clearance.
CAUTION!
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13-27
Bearing -1- is installed on the oil pump side of the cylinder block, and
bearing -4- on the dual-mass flywheel side of the cylinder block.
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13-28
Crankshaft dimensions
Reconditioning dimension Crankshaft journal diameter mm (in.) Connecting rod journal diameter mm (in.)
maximum size (from nominal) -0.022 (0.00087) -0.022 (0.00087)
Standard (nominal dimension) 65.00 (2.559) 54.00 (2.126)
minimum size (from nominal) -0.042 (0.00165) -0.042 (0.00165)
maximum size (from nominal) -0.022 (0.00087) -0.022 (0.00087)
1st undersize (nominal dimension) 64.75 (2.549) 53.75 (2.116)
minimum size (from nominal) -0.042 (0.00165) -0.042 (0.00165)
maximum size (from nominal) -0.022 (0.00087) -0.022 (0.00087)
2nd undersize (nominal dimension) 64.50 (2.539) 53.50 (2.106)
minimum size (from nominal) -0.042 (0.00165) -0.042 (0.00165)
maximum size (from nominal) -0.022 (0.00087) -0.022 (0.00087)
3rd undersize (nominal dimension) 64.25 (2.530) 53.25 (2.096)
minimum size (from nominal) -0.042 (0.00165) -0.042 (0.00165)
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13-29
Pistons
CAUTION!
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13-30
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13-31
- Insert ring at right angle from top and slide down into lower cylinder
opening until approx. 15 mm from lower edge of cylinder.
Piston ring End gap, new mm. (in.) Wear limit mm.
(in.)
1 0.35-0.50 mm (0.014-0.020 1.0 mm (0.039 in.)
(compression) in.)
2 0.50-0.70 mm (0.020-0.028 1.4 mm (0.043 in.)
(compression) in.)
3 (oil scraper) 0.25-0.50 mm (0.010-0.020 0.8 mm (0.031 in.)
in.)
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13-32
Note:
CAUTION!
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13-33
Notes:
- Mark connecting rod bearing caps with light center punch marks before
removing.
CAUTION!
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13-34
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